Architectural maneuvering of weave geometry and stuffer layers in 3D woven structural composites for enhanced mechanical attributes under multi-mode loading

Abstract Advancements in lightweight structural design have established 3D woven composites as next-generation materials, offering superior through-thickness impact properties and enhanced damage tolerance over conventional laminates. This study investigates the synergistic influence of architectural maneuvering via binder (Z) reinforcement pathways and stuffer-layer configuration on the mechanical attributes of 3D orthogonal woven fabric-reinforced composites (3DOWFRCs) under multi-mode loading. Eight distinct preforms, comprising orthogonal plain (1 × 1) and matt (3 × 3) weave architectures with 4 to 10 stuffer layers, were fabricated using vacuum-assisted resin transfer molding to ensure uniform fiber-volume fractions. Comprehensive tensile, low-velocity impact (LVI), and compression-after-impact (CAI) tests, supplemented by X-ray micro-computed tomography (µCT), elucidated internal damage progression. Increasing stuffer layers of 3DOWFRCs enhanced fiber-volume fraction and structural integrity, improving energy absorption, delamination suppression, and post-impact strength retention. The matt 3 × 3 architecture exhibited superior energy absorption, higher impact toughness, and 85% post-impact strength retention, outperforming the plain 1 × 1 weave. µCT analysis confirmed that longer binder float lengths and reduced cross-over points facilitated improved resin infiltration, lowering void content and promoting uniform stress dissipation through progressive fiber–matrix shear. These experimental findings establish a structural design framework for tailoring 3DOWFRC architectures with optimized energy absorption and superior damage tolerance for advanced engineering applications.